WAFIOS wire and tube processing machinery

WAFIOS machinery: CNC wire bending machines, tube bending centers, spring coiling equipment, and stator hairpin production systems.

WAFIOS AG: German manufacturer of wire and tube bending machinery

Headquartered in Reutlingen since 1893, WAFIOS AG designs high-precision machinery for wire and tube processing. The enterprise manufactures CNC bending centers, spring coiling machinery, and dedicated fabrication units for electric mobility components.

Leading machine manufacturing facility in Reutlingen operating continuously since 1893
Specialized CNC systems for industrial wire bending, tube forming, and spring coiling
Advanced manufacturing equipment for stator hairpins and electric vehicle busbars
Proprietary WPS 3.2 EasyWay digital programming interface for high-precision forming

WAFIOS CNC wire bending machines of BM, BMZ, and BQ series

WAFIOS machinery provides two- and three-dimensional bending of wire with diameters from 1.5 to 16 mm. Units feature rotating bending heads, servo-driven feed drives, and interchangeable rollers, maintaining high geometry repeatability without surface damage.

Processing structural, stainless, and spring wire within diameters from 1.5 to 16 mm
Multi-axis rotating bending heads engineered for high-speed spatial workpiece forming
Transfer bending centers of BQ series with flattening, threading, and cutting stations
Precision feed rollers and guide bushings fabricated from wear-resistant tool alloys

WAFIOS tube bending centers and machines of TWISTER² and BMZ series

WAFIOS tube bending units are engineered for cold forming of thin-walled and structural metal tubes. Systems provide clockwise and counter-clockwise bending within a unified cycle, featuring mandrel assemblies and adaptive springback compensation for automotive tubing.

Cold bending of hydraulic, fuel, and brake lines featuring intricate spatial layouts
Right-hand and left-hand bending within a continuous cycle without part reclamping
Mandrel assemblies and clamping dies preventing wall wrinkling on thin-walled tubes
Seamless integration with automatic hopper loaders and robotic unloading arms

WAFIOS spring coiling machines of F, FSE, FUL, and SNA series

FUL and SNA series units deliver high-speed coiling of compression, torsion, and extension springs, alongside wave spring rings. Systems incorporate optical pitch and diameter measuring sensors, dynamic servo cutting blades, and spring end grinding units.

High-speed winding of cylindrical, conical, and barrel-shaped compression springs
Multi-axis control of coil pitch geometry paired with optical sorting gauges
Dedicated SNA series automated units for fabricating single and multi-turn wave springs
Wear-resistant wire guide wedges, winding arbors, and carbide cutoff blades

WAFIOS e-mobility manufacturing systems for Hairpins and Busbars

The FMU E, SpeedFormer, and BMF machine lines are designed for series manufacturing of traction motor components. Systems perform 3D bending of stator hairpin conductors and busbars while safeguarding the delicate enamel insulation coating against cracking.

High-speed spatial forming of U-pin and I-pin stator conductor components
Clean-forming tooling preserving enamel coating integrity against dielectric defects
BMF series machines for bending insulated copper and aluminum electrical busbars
Integration with inline laser enamel stripping and terminal coining stations

WAFIOS straightening and cutting machines for smooth and reinforcing steel

WAFIOS R and RE series machinery is engineered for high-speed pay-off, multi-roller straightening, and precision cut-to-length operations. Systems feature rotary straightening arbors, flying shear cutting modules, and sorting racks, delivering straight wire bars.

High-output straightening of smooth drawn wire and ribbed reinforcing steel rods
Rotary straightening arbors equipped with carbide dies for precision rod straightness
Flying shear servo cutting heads delivering exact length tolerances on the fly
Interchangeable powered decoilers, capstan payoffs, and automated collecting cradles

Industrial heritage and engineering milestones of WAFIOS AG

Headquartered in Reutlingen, Germany, WAFIOS AG has maintained a pioneering position in wire and tube forming technology for more than one hundred and thirty years.

The enterprise combines robust structural mechanics with advanced multi-axis digital servo automation, defining rigorous industrial benchmarks across international manufacturing sectors.

Machinery portfolios from the brand operate within automotive facilities, electrical engineering plants, aerospace production halls, and dedicated spring fabrication plants globally.

Continuous kinematic refinement and implementation of proprietary WPS EasyWay control software provide operators with dependable uptime throughout heavy-duty industrial shifts.

Kinematics and tooling systems of multi-axis wire bending units

Automated systems of the BM and BMZ series alongside BQ transfer centers are engineered for high-speed spatial forming of wire components featuring complex geometries.

Workpiece positioning is executed via dynamic servo motors driving calibrated feed rollers that prevent slippage and protect workpiece surface integrity.

Tooling assemblies encompass wear-resistant carbide bending pins, pivoting arbors, wire guide bushings, shear cutoff assemblies, and end-flattening dies.

Precision fabrication of every tool element within tight tolerance margins ensures repeatable bending angles and contour radii across high-volume production schedules.

Cold mandrel bending technology for thin-walled tubing lines

TWISTER² bending centers and BMZ semi-automatic machines deploy advanced cold forming techniques for automotive hydraulic, brake, and fuel lines without profile distortion.

The capability to alternate clockwise and counter-clockwise bending within a continuous cycle eliminates collision with machine frame elements and removes secondary handling.

To prevent wrinkling and wall thinning around tight bend radii, systems utilize articulated ball mandrels, clamping dies, and adaptive wiper plates.

Precise balancing of clearance gaps between tube gauges and forming dies delivers tight alignment and leak-tight reliability for critical fluid-handling assemblies.

High-speed coiling and end grinding technology for spring series

Automated coiling machines of the F, FSE, and FUL series provide high-speed fabrication of cylindrical, conical, and variable-pitch compression, torsion, and extension springs.

Non-contact optical vision systems monitor coil outer diameters and free length in real time, automatically sorting parts meeting strict quality parameters.

Tooling setups feature carbide pitch wedges, wire guide plates, coiling pins, and heavy-duty cutoff knives fabricated from hardened tool alloys.

For mission-critical suspension and valve springs, automated dual-end grinding units establish parallel end surfaces with minimum angular deviation across supporting coils.

Stator hairpin and power busbar manufacturing for electric transport

The rapid automotive transition toward electric propulsion spurred the development of specialized automated equipment for forming insulated copper conductors.

WAFIOS FMU E and SpeedFormer machines carry out three-dimensional bending of U-pin and I-pin stator windings for traction motors with tight geometric tolerances.

A primary process objective requires maintaining dielectric insulation enamel integrity during aggressive bending motions.

Dedicated bending modules equipped with polished forming jaws alongside BMF series servo axes for rectangular busbars ensure high component quality without microfissures in dielectric coatings.

Routine maintenance protocols and technical spare parts selection

The operational longevity and precision of WAFIOS machinery depend upon systematic inspection of kinematic clearances, timely lubrication renewal, and replacement of friction contact pairs.

Routine technical procedures incorporate spindle bearing checks, feed roller alignment, optical sensor calibration, and safety circuit verification.

Scheduled maintenance schedules require periodic replacement of hardened feed rollers, wire guide bushings, pneumatic directional valves, brake couplings, and protective bellows.

Systematic identification using serial numbers and assembly diagrams allows factories to maintain strategic component reserves and eliminate unexpected downtime.

WAFIOS and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of WAFIOS and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.